Seamless knitting, as a new technology, has a great potential in the development of lingerie products. Bra knitting using seamless knitting technology is a difficult engineering problem due to the lack of knowledge on how to achieve proper underband tension and cup strain for optimal comfort and shape. In this study, we aim at identifying the key knitting parameters and experimentally investigating their relationships with the knitted bra tension. The knitting parameters under investigation were loop density, elastic yarn tension, cover yarn tension and nylon yarn tension. Factorial experimental design was used to explore the most significant factors affecting the underband tension and cup strain of seamless knitted bra. The results show that the loop density and elastic yarn tension were the two main factors affecting the underband tension. The cup strain was mainly affected by the loop density. Empirical prediction equations have been established to estimate the underband tension and cup strain from knitting parameters.

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